Patent GB-987574-A (GB)
Title: Improvements in decorative processes
IPC: B44F5/00
Filed: 1961-06-06
Abstract: 987,574. Coated sheet materials. J. LUC. June 6, 1961 [June 16, 1960], No. 20406/61. Headings B2B and B2E. [Also in Divisions B5 and B6] A plate, sheet or film having a reproducible decorative pattern in a layer of viscous material capable of subsequent setting on its surface is produced by introducing the layer of material between the surfaces of two sheets, plates or films, at least one of the surfaces being flexible, and one of the surfaces is moved progressively into pressure contact with the second surface, and the surfaces are progressively separated, the pressure applied to, and the speed of separation of the surfaces being controlled, whereby a predetermined pattern is produced. The separation may occur at substantially constant speed. The pattern may be controlled by controlling the viscosity of the viscous material. At least one surface is in the form of a non- continuous web. One or both surfaces is or are in the form of an endless belt or other endless carrier. The viscous material may be coloured or contains minute particles, or a coloured ink or paint which may comprise pigment in a clear medium or one which becomes clear on drying, e.g. a polymeric resinous emulsion such as of polyvinyl acetate or butyrate, vinyl copolymer, polystyrene, acrylic and methacrylic copolymer, polymethacrylic ester, higher alkyl polymethacrylate, and may contain particles, e.g. of mica or metal. An electrostatic charge may be applied to part or all of the surface of the sheet, plate or film prior to or during the application of the paint or ink or while the surfaces are in contact. The pattern produced on the surface of the sheet, plate or film, e.g. of metal, hard rubber or flexible plastic, may be transferred to a further surface, e.g. a textile fabric. The viscous material when hardened form a protective layer on the surface of the sheet, plate or film in areas corresponding to the pattern and the surface is then subjected to a further treatment to leave the pattern in relief. The further treatment may be on etching process, or when the sheet, plate or film is of metal the further treatment may be an electrolytic treatment, e.g. plating. The viscous material may be constituted by the softened outer portions of one or both surfaces, e.g. softened by means of heat or a solvent, or may be a thickened solution of the material forming one of the surfaces. A layer of resin in a soft viscous condition with or without pigment, e.g. viscous resin emerging from a homogenizing machine, may be pressed between the two surfaces so that on separation patterns are produced on both surfaces of the layer. During separation the layer may be split along its thickness to produce two separate films. Apparatus for carrying out the method of forming the pattern comprises means for driving a web and a sheet of smooth surfaced material along paths over part of which they are in contact with one another, a device for applying viscous material to the surface of the web or sheet at a point before it makes contact with the other, and means for pressing the web and sheet together with a controlled pressure over the region in which they are in contact with one another. The sheet may be flexible and constitutes a second web. One or both webs may be wound on to rollers which provide the necessary driving tension for pulling the webs through the apparatus. One of the webs may be an endless carrier surface. The apparatus may include means to drive a third web in contact with the endless carrier surface so that the pattern produced on the surface is transferred to the third web. Both webs may be wound on to rollers and both webs are supported by endless carrier surfaces over the region in which they are in contact with one another. As shown in Fig. 2, web of synthetic resin 6 is coated with viscous material from devices 8 and is pressed into contact with web 11 by endless belt 9 and device 15, separated and dried at 17 prior to winding on rolls 18. In Fig. 3, web 20 coated with paint or ink by devices 30 is pressed into contact with web 21 by pressure devices 35, separated and dried prior to being reeled on reels 37. Fig. 4 shows rigid sheet material 40 passing between endless belts 43, 44 and is supplied with viscous material from hopper 48. In Fig. 5, viscous material from hopper 57 is applied to rigid sheet 55 prior to passage between endless belts 58, 59. As shown in Fig. 6, patterns are formed on endless carrier surfaces 70, 71 and third and fourth webs 76, 77, e.g. paper or textile, are driven so as each to move in contact with one of the carrier surfaces, so that the pattern produced on each carrier surface is transferred to one of the webs. As shown in Fig. 7, the apparatus may include a pair of driven endless carrier surfaces 97 which move together over part of their circuits so as to receive between them a layer of resin 95 in a plastic condition direct from a homogenizing machine. Each carrier surface 97 may be a belt which is driven around a generally triangular circuit, along one side of which it moves with the other belt to receive the layer of resin 95 from the homogenizing machine, which when it reaches the point where the belts separate, is split along the middle of its thickness, the two halves 95a, 95b each passing along the second side of the triangular path of the respective belt before being separated from it, this side of the path including cooling or drying equipment 102 to facilitate separation of the web and the belt.